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area with a grinding disk or block.
Refer to Table 2 for data about the scarf
size.
WARNING: DO NOT GET ACETONE ON YOUR SKIN. ACETONE CAN CAUSE
SKIN DISEASE.
WARNING: DO NOT BREATHE ACETONE FUMES. ACETONE FUMES CAN
CAUSE DISEASE.
CAUTION: THERE MUST BE NO GREASE OR DUST ON THE REPAIR AREA.
GREASE AND DUST PREVENT A GOOD BOND.
(6) Clean the area of the repair. Use acetone only if any grease or dirt
comes to the surface of the repair.
(7) Cut and shape a piece of foam core to replace
the damaged foam core that you removed in step
4.
Use a sharp knife to cut the foam.
(8) Prepare the layers of cloth that you will need to
laminate on the inner surface of the foam core.
Refer to the lay-up drawing for the
related structure for data about the cloth
type and orientation.
AIRCRAFT
Standard Practices and
Structures
DA 40 Series
AMM
Detail Steps/Work Items Key Items/References
Page 220
20 Sep 2007 51-20-00 Doc # 6.02.01
Rev. 5
WARNING: DO NOT GET RESIN ON YOUR SKIN. RESIN CAN CAUSE SKIN
DISEASE.
WARNING: DO NOT GET RESINS, HARDENERS OR SOLVENTS IN YOUR
MOUTH OR IN YOUR EYES. THESE CHEMICALS CAN CAUSE
DISEASE.
(9) Prepare the foam core for inserting in the repair:
S Apply a thin coat of resin to the foam core.
S Apply a coat of thickened resin to the foam
core.
S Laminate the inner layers of cloth onto the
inner surface of the foam core. Make sure
that the fibers in the cloth point in the correct
direction.
Refer to Paragraph 6 in this Section.
Use one of the 2 methods given in
Paragraph 5 of this Section.
(10) Apply a thin coat of resin to the area to be
repaired.
(11) Put the foam core and inner laminate into position
in the repair.
(12) Pre-cure the repair. Refer to Paragraph 7 in this Section.
(13) Use a sanding disk or block to contour the foam
core to the correct shape.
Refer to Figure 4.
(14) Clean the repair.
(15) Apply a coat of thickened resin to the foam core
of the repair.
(16) Apply a thin coat of resin to the scarfed edges of
the outer laminate of the repair.
(17) Repair the outer laminate. Use one of the 2 methods given in
Paragraph 5 of this Section.
(18) Pre-cure the repair. Refer to Paragraph 7 in this Section.
(19) Post-cure the repair. Refer to Paragraph 7 in this Section.
(20) When the repair is fully post cured, remove any
peel ply and sand smooth the surface of the
repair.
AIRCRAFT
DA 40 Series
AMM
Standard Practices and
Structures
Detail Steps/Work Items Key Items/References
Doc # 6.02.01
Rev. 5 51-20-00 Page 221
20 Sep 2007
(21) Contour the repair so that the final surface level
of the repair is slightly lower than the original
surrounding area.
Use 150 grit sanding paper.
To allow for the paint coat.
(22) Apply filler(s) and paint coat. Refer to Paragraph 8 in this Section.
AIRCRAFT
Standard Practices and
Structures
DA 40 Series
AMM
Page 222
20 Sep 2007 51-20-00 Doc # 6.02.01
Rev. 5
Intentionally left blank
AIRCRAFT
DA 40 Series
AMM
Standard Practices and
Structures
Doc # 6.02.01
Rev. 5 51-30-00 Page 1
20 Sep 2007
Section 51-30
Materials
1. General
You must only use approved materials from approved sources to repair the DA 40 airplane.
% Note: If the approved material for the repair work is not available please contact Diamond
% Aircraft Industries for information about alternative materials.
2. Approved Materials
A. Resin system
Resin : L 285
Hardener : H 286
Mixture : 100 parts resin and 40 ± 2 parts hardener (by weight)
% CAUTION: THE RESIN SYSTEM L940/ H286 IS A SELF EXTINGUISHING SYSTEM
% AND IS APPROVED FOR COWLING PARTS ONLY.
% Resin : L 940 (self extinguishing)
% Hardener : H 286
% Mixture : 100 parts resin and 21 ± 2 parts hardener (by weight)
Supplier : Scheufler
Am Ostkai 21/22
D-70327 Stuttgart, Germany
Phone : +49-711-323081
Fax : +49-711-3280041
B. Glass fiber cloth
WLB No.
(German
aviation
standard)
Weave Weight per
unit area
[g/m²]
Interglas Type Porcher Type
8.4548.60 2/2 twill 163 92110 917
8.4551.60 2/2 twill 280 92125 3063
8.4554.60 2/2 twill 390 92140 1989
8.4520.6 UD 220 92145
8.4525.60 UD 425 92146
AIRCRAFT
Standard Practices and
Structures
DA 40 Series
AMM
Page 2
20 Sep 2007 51-30-00 Doc # 6.02.01
Rev. 5
All cloth types consist of alkali free E-glass with I 550 or PT 55 finish and comply with LN 9169
　
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